Integrated Guide to Production Part Approval: AIAG PPAP + VDA PPA

In the global automotive industry, the ability of suppliers to consistently deliver components that meet customer requirements is a fundamental expectation. Two major standards define how suppliers must demonstrate this capability:

• AIAG PPAP (Production Part Approval Process) – widely used in North America
• VDA PPA (Production Process and Product Approval) – used by German OEMs and their supply chains

This guide integrates both standards into a single structured approach, enabling suppliers to meet the expectations of major OEMs such as GM, Ford, Stellantis, Volkswagen, BMW, and Mercedes-Benz.

🎯 Purpose of PPAP/PPA

The core objectives of both AIAG PPAP and VDA PPA are to:

• ✅ Verify that the supplier fully understands all customer engineering and specification requirements
• ✅ Confirm that the production process can consistently manufacture conforming parts
• ✅ Ensure production readiness before serial launch
• ✅ Provide documented evidence of compliance to customer requirements

📌 When Approval Is Required

PPAP or PPA submission and customer approval are typically required in the following situations:

• Introduction of a new part or product
• Engineering or design changes
• Tooling changes, replacements, or refurbishments
• Relocation of the production site
• Change of supplier or material source
• Tooling inactivity for more than 12 months
• Reuse of existing parts in new projects (carry-over)
• Upon customer request

🔔 Both AIAG and VDA standards require that customers are notified and approvals are obtained before implementing such changes.

📄 Unified Documentation Requirements

The following list combines the 18 PPAP elements from AIAG with the corresponding VDA PPA requirements. All documents should be prepared unless explicitly waived by the customer.

• Design Records – Engineering drawings, CAD data, GD&T
• Authorized Engineering Change Documents – Approved changes not yet reflected in drawings
• Customer Engineering Approval – Often documented in EMPB (VDA)
• Design FMEA – Risk analysis using harmonized AIAG-VDA format
• Process Flow Diagram – Visual mapping of the manufacturing process
• Process FMEA – Risk analysis for manufacturing failures
• Control Plan – Product/process characteristic controls and reaction plans
• Measurement System Analysis (MSA) – Gage R&R, bias, linearity, stability
• Dimensional Results – Actual measurements with drawing references
• Material / Performance Test Results – Chemical, physical, and functional testing
• Initial Process Studies – Cpk/Ppk or justified alternatives
• Qualified Laboratory Documentation – ISO/IEC 17025 accreditation
• Appearance Approval Report (AAR) – For appearance-critical parts
• Sample Production Parts – From actual production run
• Master Sample – Retained reference sample
• Checking Aids – Fixtures, templates, gauges
• Customer-Specific Requirements – OEM-specific forms, portals, formats
• Part Submission Warrant (PSW) / EMPB – Signed declaration of conformity

📦 Submission Levels

AIAG PPAP Levels

• Level 1: PSW only
• Level 2: PSW + limited supporting data
• Level 3: PSW + full documentation (default)
• Level 4: PSW + customer-defined requirements
• Level 5: PSW + full documentation + on-site review

VDA PPA Levels

• Level A: Product samples only
• Level B: Samples + selected documentation
• Level C: Full documentation (default)
• Level D: Full documentation + audit or on-site review

📊 Process Capability Requirements

AIAG Criteria:

• Cpk/Ppk ≥ 1.67 → Approved
• 1.33 ≤ Cpk/Ppk < 1.67 → Conditional approval (monitoring required)
• Cpk/Ppk < 1.33 → Corrective actions required

VDA Criteria:

• Cp/Cpk ≥ 1.33 recommended
• Alternative methods (e.g., control charts, long-term capability) acceptable if justified and agreed with the customer

📏 Measurement System Analysis (MSA)

• AIAG: Requires Gage R&R, bias, linearity, and stability studies
• VDA: Requires test equipment capability (Cg/Cgk) or equivalent

Standardized measurement methods may reduce MSA requirements if mutually agreed upon.

📋 Final Approval Documents: AIAG vs. VDA

Item	AIAG	VDA
Final Form	PSW	EMPB
Language	English	Often German
Signature	Supplier + Customer	Supplier + OEM Quality
Traceability	Revision control	Maturity level tracking

⚙️ Special Cases

Bulk Materials

• AIAG: Use Bulk Material Checklist
• VDA: Risk-based sampling and documentation

Tires

• AIAG: AAR and master samples not required
• VDA: Emphasis on performance testing and mold certification

Truck Industry

• AIAG: Truck-specific PSW form
• VDA: May require additional documentation for low-volume parts

📊 Summary Table

Topic	AIAG PPAP	VDA PPA
Origin	USA (AIAG)	Germany (VDA)
Structure	18 fixed elements	Risk-based, flexible
Submission Levels	1–5	A–D
Final Document	PSW	EMPB
Audit	Level 5	Level D
Software	Optional	Often required
Legal Compliance	Optional	Required if applicable
Environmental	Optional	Required if applicable

✅ Best Practices for a Successful PPAP/PPA

• Start preparations early and integrate with APQP, DFMEA, PFMEA
• Confirm submission levels and customer-specific requirements at project kickoff
• Maintain traceable records of raw data, test results, equipment IDs, operators, and dates
• Use a centralized, controlled digital repository for documentation
• Engage customer quality teams early if capability or validation results are marginal

💡 Key Takeaway

A complete, traceable, and well-organized PPAP/PPA package — aligned with APQP deliverables and risk analysis — reduces approval cycle time, shortens launch timelines, and improves product reliability in serial production.

By integrating AIAG and VDA approaches, suppliers position themselves for success across global automotive OEM programs.

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